Modular steel building with internal air flow passages

ABSTRACT

An all steel building comprised of prefabricated modules that are welded together in series to form a building of the desired shape and dimensions. Each module includes an inner steel wall, an outer steel wall, and a plurality of separator bars spacing the inner wall from the outer wall so as to (1) form laterally extending passages between the walls and (2) to minimize undesirable heat transfer through the walls. The roof is constructed in a similar manner with longitudinally extending passages and a central return air duct. An air blower forces air to circulate through the passages in the walls and between the roof and ceiling after being heated or cooled to the temperature desired within the building. A suction pump draws the air, after circulation through the building, back into a return duct in the central partition wall.

[451 Sept. 5, 1972 Primary Examiner-Edward J. Michael Att0mey-Schellin & Hoffman [57] ABSTRACT An all steel building comprised of prefabricated modules that are welded together in series to form a building of the desired shape and dimensions. Each module includes an inner steel wall, an outer steel wall, and a plurality of separator bars spacing the inner wall from the outer wall so as to (1). form laterally extending passages between the walls and (2) to minimize undesirable heat transfer through the walls. The roof is constructed in a similar manner with longitudinally extending passages and a central return air duct. An air blower forces air to circulate through the passages in the walls and between the roof and ceiling after being heated or cooled to the tempera- United States Patent Erickson et al.

[54] MODULAR STEEL BUILDING WITH INTERNAL AIR FLOW PASSAGES [72] Inventors: Walter C. Erickson, 240 E. 108th St., Chicago, 111. 60628; Harry Pon, PO. Box 1191, Burns, Oreg. 97720 [22] Filed: Dec. 29, 1970 v [21] Appl. No.: 102,395

[51] Int.

[58] Field of Search..........237/l [56] References Cited UNITED STATES PATENTS Telford......................

B k g ture desired within the building. A suction pump at draws the air, after circulation through the building,

2,465,184 3/1949 Alderman....................237/69 back into a return duct in the central partition wall.

2,596,300 5/1952 Smith 2,598,841 6/1952 Scott ....237/69 12 Claims, 10 Drawing Figures FATE "THI 5 W3 SHEET 1 0F 4 INVENTORS WALTER C. ERICKSON 8\ HARRY- PON ATTORNEYS PATENT ED 5 I972 SHEEI 2 0F 4 INVENTORS WALTER C. ERICKSON 8| HARRY PON PATENTEBSEP 5 m2 SHEET 3 [IF 4 INVENTORS WALTER C. ERICKSON 8: HARRY PON MODULAR STEEL BUILDING WITH INTERNAL AIR FLOW PASSAGES BACKGROUND OF THE INVENTION 1. Field of the Invention The instant invention relates generally to steel buildings of modular construction wherein a series of prefabricated modules are welded together at a building site. More particularly, the invention relates to modular, welded, all steel buildings wherein laterally extending passages in the walls communicate with longitudinally extending passages in the roof and terminate in a central return duct. The passages and return duct serve to freely circulate heated and/or cooled air between the spaced inner and outer walls of the building.

2. Description of the Prior Art Buildings comprised of a series of metal sections joined together at a building site are known to the construction industry. Exemplary buildings are disclosed by U.S. Pat. No. 3,478,477, granted to Poyton, and US. Pat. No. 3,500,596, granted to Andersson.

Poyton relies upon precise interlocking joints defined between adjacent sheet metal sections in order to join the sundry sections together without resorting to special fastening devices. However, considerable skill must be exercised in the fabrication of such joints, and similar skill must be employed on the job site in properly aligning the mating members that form the joints. Furthermore, since the designs of the joints formed at the junction of the floor and wall were different than the joints formed at the junction of the wall and the roof, etc., very few parts could be standardized for economical techniques.

Andersson discloses a building comprised of prefabricated standardized sections of corrugated metal. The standardization of the metal sections led to welding or riveting adjacent sections together, thus obviating the necessity for interlocking joints and/or special fasteners between sections with attendant economics over the Poyton structure. However, reliance upon corrugated sheet metal sections in Andersson calls for the introduction of vertical wooden spacing bars into the open trapezoidal channels formed between the spaced corrugated interior and exterior walls. Additionally, the Andersson structure requires a metal floor also formed of the above noted corrugated metal sections. Manifestly, the spacing bars and the metal floor corrugations add to the bulkiness and cost of fabricating and assembling the corrugated metal sections of the Andersson building.

SUMMARY mass-production manufacturing.

open into a central return duct. The passages received air from a forced air blower, and circulate the air throughout the building, after heating or cooling same. The constant air circulation eliminates the moisture condensation problem that has plagued conventional metal or wood buildings with solid walls.

Additionally, the persistent problem of heat transfer or loss through solid metal walls to the atmosphere is obviated in the instant building by minimizing the amount of steel that extends from inner wall to the outer wall. The inner wall and the outer wall as well as the roof and ceiling are separated from each other by spacer bars to increase circulation therebetween.

Furthermore, the instant building has sufiicient structural rigidity that the conventional metal floor section interconnecting the walls can be omitted; consequently, the walls can be secured to a poured concrete slab so that the slab can be used as a floor with attendant economies in fabrication and assembly costs.

Other objectives achieved by the instant building are resistance to rust, rot, fire, insects, mildew, etc. as well as ease of assembly and maintenance.

Yet additional objectives and advantages of the invention will become apparent from the following description of a preferred embodiment of the all steel, modular building.

DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of an assembled, all steel modular building constructed in accordance with the principles of the instant invention;

FIG. 2 is an exploded perspective view of the modular building illustrated in FIG. 1;

FiG. 3 is a top plan view of a portion of the roof of the modular building;

FIG. 4 is an elevational view of a portion of one end wall of the modular building, such view being taken along line 4-4 in FIG. 3 and in the direction indicated;

FIG. 5 is a vertical cross sectional view through one of the windows of the building, such view being taken along line 55 in FIG. 4;

FIG. 6 is a fragmentary top plan view of an end wall and the front wall of the building, the roof therefor having been removed for the sake of clarity;

FiG. 7 is a diagrammatic perspective view of the assembled building with the roof and outer walls removed to show the flow of air through the building;

FIG. 8 is a floor plan of the building, such viewing depicting the position of the heating and cooling means for the air flowing through the building;

FIG. 9 is a detailed view of the metal plates secured to the foundation prior to the erection of a modular, section of the building; and

FIG. 10 is a detailed view of the metal plates secured to the foundation after the inner and outer walls of a modular section have been secured thereto.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now in greater detail to the drawings, wherein identical elements are indicated by identical reference numerals, FIGS. 1 and 2 show a modular, all steel building 10 constructed in accordance with the principles of the instant invention. FIG. 1 shows building after the modular components have been joined together, while FIG. 2 shows the modular components as they are shipped to the job site. Although building 10 assumes the form of a one story, ranch residential dwelling in the preferred embodiment, the unique principles of design, construction and assembly set forth hereinafter are equally applicable toall types of residential and commercial dwellings.

Building 10 comprises a first or end module 12, a second or intermediate module 14, a third or central module 16, a fourth or intermediate module 18, and an optional fifth or end module constituting a garage 20.

Each module includes, inter alia, a front wall 22, a rear wall 24, and a roof 26. Module 12 also includes an end wall 28, and module'20, or the garage, includes an end wall 30. In lieu of a front wall, the garage has a conventional sliding door 32. Each module is open along its base, for the front, end and rear walls are joined securely to a concrete foundation in a manner described subsequently.

End module 12 also includes windows 34 and 36 in end-wall 28, and window 38 in front wall 22. Intermediate modules 14 and 18 include windows 40 and 42, respectively, in front wall 22. Central module 16 has a door 44 to permit entry into the interior of building 10. Obviously, an appropriate number of doors and windows (not shown) will be spaced along rear wall 24 of building 10.

A series of vertically extending steel columns are located along front and rear walls of building 10, and at the four corners thereof, to enhance its structural rigidity and aesthetic appeal. Furthermore, as shown in FIG. 6 anddiscussed hereinafter, the columns house the heater elements which heat the interior of building 10.

Those columns that are visible in FIGS. 1 and 2 are designated by reference numerals 46, 48, 50, 52, 53, 54 and 55, respectively. The columns spaced along rear wall 24 are not visible in the drawings, but are identical in shape, location and function. As shown in FIG. 6, the columns along the expanse of front wall- 22 and rear wall 24 are U-shaped, when viewed in horizontal cross section. The columns at the corners of the building are C-shaped, when viewed in horizontal cross section. The space within the column is in communication with the space between the walls and between the ceiling and the roof.

The columns are interconnected at their upper ends by a horizontally extending ledge that extends around the perimeter of building 10. The ledge is rectangular in shape when viewed in vertical cross section. The portion of the ledge which extends along front wall 22 is identified by reference numeral 56, while the portion of the ledge which extends along end wall 28 is identified by reference numeral 58. The ledge continues in similar manner along rear wall 24 and end wall 30, and is identified by reference numerals 60 and 62, respectively.

Ledge segments 56, 58, 60 and 62 define an unbroken overhang that extends outwardly beyond the walls of the building. Thus, snow, rain, debris and the like will not pass straight downthe outer surface of the exterior walls and constantly blur the view from the windows. A sturdy, weather resistant receptacle 64 is provided in proximity to end wall 28. The receptacle houses an air cooling unit, a forced air blower, and an air filtering and humidifying unit of conventional design (not shown).

FIG. 3 is a view of the rear left quadrant of roof 26, with fragments broken away for the sake of clarity. Ledge segments 58 and 60 extend outwardly beyond end wall 28 and rear wall 24, respectively. Each wall in the modular home, and roof 26 as well, is made up of an outer metal wall that is exposed to the climatic elements, and an inner wall. The outer walls are identified by the addition of a prefix of 100 to the reference numeral previously used in FIGS. 1 and 2 for identification purposes, while the corresponding inner walls are identified by the addition of a prefix of 200. For example, the outer wall of end wall 28 is identified by reference numeral 128 and the corresponding inner wall is identified by reference numeral 228.

Roof 26 is rigidly supported by a series of intersecting metal braces 64 and 66 which extend beneath the exterior metal skin. Ceiling 226, the equivalent of an inner wall for the roof, is joined to the roof by a series of I-l-beams 68 which areseated upon a seriesof II- shaped bars 70 (see FIG. 4). Beams 68 and bars 70 are welded together. Similarly, roof 26 is welded to the upper surface of beam 68 and ceiling 226 is welded to the lower surface of bar 70 prior to being shipped from the factory. The traces of the webs of beams 68 are indicated by the horizontally extending dotted lines in FIG. 3. Insulation 69 partially fills the space between the roof and the ceiling. FIG. 4 illustrates that a centrally located interior partition wall extends throughout the length of the house to lend support to roof 26 in addition to that support provided by the outer and inner walls. The partition wall includes spaced parallel walls 72 and '74 and the space between walls 72 and 74 is filled with fiberglass insulation 76. A return air duct-78 is located at the top of the partition wall, and the duct communicates with theair cooling, filter and humidifying units housed in receptacle 64 at the exterior of the house.

The rear half of end wall 30, when viewed from the interior of building 10, is illustrated in FIG. 4. Thus, it can be seen that interior wall 230 is rigidly supported by a series of intersecting metal braces 80 and 82. At spaced intervals, the pattern of intersecting braces is interrupted to allow the introduction of a double thickness window 84 into the space defined between the interior and exterior walls.

The spacing between the interior and exterior walls is maintained constant throughout building 10 by horizontally disposed wall separator bars 86. These bars minimize the amount of through-steel utilized in building 10 and thus reduce significantly the undesirable transfer of heat from the outer wall through the inner wall to the interior of the building. Furthermore, bars 86 have a horizontal dimension slightly greater than the thickness of the windows so that the windows can be slipped into position between the inner and outer walls and can then be secured thereto.

FIG. 4 also shows the rear wall 24 includes an outer wall 124 and an inner wall 224. A plurality of spacer bars 88 maintain the walls in properly spaced relationship. Consequently, such space between the walls communicates freely with the space between roof 26 and ceiling 226 which, in turn, communicates with return duct 78 in partition wall 72. The continuous flow of air through such path is indicated by directional arrows in FIG. 4.

FIG. 5 shows additional details, on an enlarged scale, of the manner in which window 84 is secured in a recessed position midway between he inner and outer walls. As previously noted, window 84 comprises a first pane 85 and a second pane 87, separated by a thin layer of air 89. A caulking compound or sealing strips 91 render the window weatherproof, and insulation 93 partially fills the space between walls 130 and 230.

Window 84 is supported in a recessed position by jambs 95 and 97 which extend inwardly from the interior and exterior walls.

FIGS. 4 and 6 illustrate the heating system utilized within building 10. An elongated electric heater 90 with a series of fins 92 is housed within the columns spaced along the walls of building (e.g. column 50) and within the columns 46,48, 54 and 55 that are located at the corners of the building. A stainless steel reflector 94 is deployed behind each heater 90 for effectively heating the interior of the building. A thermostatic control 96 is provided for each heater element 90, and a channel 98 accommodates the conduits needed to supply power to the heater elements. The thermostatic controls and the wiring therefor are installed in each module prior to shipment from the factory. An access door 99 on the outside of each column permits facile servicing of the heater elements.

In FIGS. 7 and 8, roof 26 has been removed from all of the modular sections except garage module 20 so that the circulation of air throughout the building can be schematically represented. Air, after being drawn into receptacle 64, is then filtered, humidified, and then blown via conduits 100 and 102 into the laterally extending passages defined between the interior and the exterior walls of the building.

A suction pump (not shown) is also housed within receptacle 64 and communicates via conduit 104 with return duct 78 that runs laterally along the entire length of building 10. The blower supplies positive pressure to the air, and the suction pump, supplies negative pressure thereto. As indicated by directional arrows in FIGS. 7 and 8, the pressure differential insures efficient circulation of the air through the laterally extending passages defined between the walls of the building, thence into the longitudinally extending passages defined between the ceiling and the roof, and finally into the return duct 78 in the partition wall. The air is selectively heated during the course of its circulation by heaters 90 housed within the columns of the buildiIG. 8 shows an exemplary floor plan for modular building 10. It will be appreciated that an individual heater element 90 and stainless steel reflector 94 is provided for each room of the house for increased comfort. The living room has two heater elements, since it is the largest room in the building. The interior walls, kitchen cabinets, inside doors and sliding closet doors are all executed in steel and are shipped to the job site as an integral part of one of the modules.

The manner in which modular building 10 is assembled on the job site is now briefly described with reference to FIGS. 9 and 10. The concrete slab is poured and metal plates 106 are secured thereto by threaded anchor bolts 108. Plates 106 are positioned on the concrete foundation in a pattern corresponding to the location of all of the walls shown in the floor plan of the building to be assembled. As previously noted, the roof and walls of the module have been welded together prior to shipment from the factory to the job site. Thus, after plates 106 have been secured in position, the bolts are removed and apertures (not shown) in the inturned flanges 109, 209 of the interior and the exterior walls are slipped over the upstanding ends of bolts 108. The bolts are tightened and the flanges are forced into engagement with plates 106 for purposes of alignment, as shown in FIG. 10. The walls of the module are then welded to plates 106 along the seams formed therebetween. Second modular section 14, with its roof, walls, partitions, shelves, closets, etc. similarly prefabricated, is then fitted onto the section of plates 106 adjacent to modular section 12. The two modular sections are then butt welded together. The remaining sections are subsequently joined together in serial fashion in a like manner.

The foregoing is but a description of a preferred embodiment of the invention which is exemplary in nature. Air vents can be formed in the garage and in the building walls to assist the circulation of air through building 10. Manifestly, the invention is not limited in scope to the specific configuration detailed above, but includes all such variations as fall within the spirit and scope of the inventive concepts embraced by the instant invention.

We claim:

1. An all metal building comprising:

a. a metal exterior wall and a metal interior wall,

b. first spacer means for retaining said walls in spaced relationship to define passages therebetween,

c. a metal partition wall extending along the length of the interior of the building,

d. duct means located in said partition wall,

e. a roof and a ceiling secured to said walls,

f. second spacer means for retaining said roof and ceiling in spaced relationship to define passages therebetween,

g. the passages between said walls communicating with the passages between the ceiling and the roof and the duct means in the partition wall,

h. means for forcing air to circulate through said passages and into said duct means, and

i. means for withdrawing air from said duct means after the air has been circulated through said passages.

2. A building as defined in claim 1 wherein metal support columns are located at spaced intervals along the exterior wall of said building.

3. A building as defined in claim 2 wherein heater means are disposed within each of said support columns.

4. A building as defined in claim 3 wherein said heater means comprises an elongated vertically oriented heater element with a plurality of fins spaced therealong, and a reflector positioned behind said heater element to direct the heat into the interior of said building.

5. A building as defined in claim 1 wherein said first spacer means comprises a plurality of horizontally extending spacer bars.

6. A building as defined in claim 1 wherein cross braces are positioned in the space between said exterior and interior walls to increase the structural rigidity of said walls.

7. A building as defined in claim 1 wherein insulation partially fills the space between said exterior and interior walls.

8. A building as defined in claim 1 wherein windows are snugly fitted into the space between said exterior and interior walls, said windows being held between outwardly extending jambs on said innerwall and inwardly extending jambs on said outer wall.

9. A building as defined in claim 1 wherein said second spacer means comprises l-l-beams and support bars, said beams being welded at one side to said roof and at the other side to said support bars, and said support bars being welded to said ceiling 10. A building as defined in claim 9 wherein insulation partially fills the passages between the ceiling and the roof.

1 1. An all metal building comprising:

a. a concrete foundation,

b. metal plates joined to said foundation for defining the outline of the building,

c. a metal exterior wall and a metal interior wall welded to said metal plates,

d. first spacer means for retaining said walls in spaced relationship to define passages therebetween,

e. a metal partition wall extending along the lengthof the interior of the building, said wall being welded to said metal plates,

f. duct means located in said partition wall,

g; a roof and a ceiling welded to said walls,

h. second spacer means for retaining said roof and ceiling in spaced relationship to define passages therebetween,

i. the passages between said walls communicating with the passages between the ceiling and the roof and the duct means in the partition wall, and

j. means for forcing air to circulate through said passages and into said duct means.

12. A building as defined in claim 11 wherein said means for forcing air to circulate comprises positive pressure blower means, and negative pressure suction means are connected to said duct means for withdrawing the air from the building. 

1. An all metal building comprising: a. a metal exterior wall and a metal interior wall, b. first spacer means for retaining said walls in spaced relationship to define passages therebetween, c. a metal partition wall extending along the length of the interior of the building, d. duct means located in said partition wall, e. a roof and a ceiling secured to said walls, f. second spacer means for retaining said roof and ceiling in spaced relationship to define passages therebetween, g. the passages between said walls communicating with the passages between the ceiling and the roof and the duct means in the Partition wall, h. means for forcing air to circulate through said passages and into said duct means, and i. means for withdrawing air from said duct means after the air has been circulated through said passages.
 2. A building as defined in claim 1 wherein metal support columns are located at spaced intervals along the exterior wall of said building.
 3. A building as defined in claim 2 wherein heater means are disposed within each of said support columns.
 4. A building as defined in claim 3 wherein said heater means comprises an elongated vertically oriented heater element with a plurality of fins spaced therealong, and a reflector positioned behind said heater element to direct the heat into the interior of said building.
 5. A building as defined in claim 1 wherein said first spacer means comprises a plurality of horizontally extending spacer bars.
 6. A building as defined in claim 1 wherein cross braces are positioned in the space between said exterior and interior walls to increase the structural rigidity of said walls.
 7. A building as defined in claim 1 wherein insulation partially fills the space between said exterior and interior walls.
 8. A building as defined in claim 1 wherein windows are snugly fitted into the space between said exterior and interior walls, said windows being held between outwardly extending jambs on said inner wall and inwardly extending jambs on said outer wall.
 9. A building as defined in claim 1 wherein said second spacer means comprises H-beams and support bars, said beams being welded at one side to said roof and at the other side to said support bars, and said support bars being welded to said ceiling
 10. A building as defined in claim 9 wherein insulation partially fills the passages between the ceiling and the roof.
 11. An all metal building comprising: a. a concrete foundation, b. metal plates joined to said foundation for defining the outline of the building, c. a metal exterior wall and a metal interior wall welded to said metal plates, d. first spacer means for retaining said walls in spaced relationship to define passages therebetween, e. a metal partition wall extending along the length of the interior of the building, said wall being welded to said metal plates, f. duct means located in said partition wall, g. a roof and a ceiling welded to said walls, h. second spacer means for retaining said roof and ceiling in spaced relationship to define passages therebetween, i. the passages between said walls communicating with the passages between the ceiling and the roof and the duct means in the partition wall, and j. means for forcing air to circulate through said passages and into said duct means.
 12. A building as defined in claim 11 wherein said means for forcing air to circulate comprises positive pressure blower means, and negative pressure suction means are connected to said duct means for withdrawing the air from the building. 